Mineral fiber nodules and method of making same

Abstract

A nodulizing machine for use in an apparatus for making loose fill insulation from mineral fibers comprises an input portal, a conduit containing a plurality of blades and an output portal. Apparatus for making loose fill insulation from mineral fibers comprises a duct extending from a source of the mineral fibers to the nodulizing machine of the present invention. The apparatus includes flow rate control means to control the flow rate of air and mineral fibers in the apparatus. A process for making loose fill insulation from mineral fibers in association with the apparatus of the invention is also disclosed.

We claim: 
     
       1. An apparatus for making mineral wool nodule insulation with enhanced insulating properties from discrete mineral wool fibres, comprising: nodulizing means having an input and output, for processing discrete mineral wool fibres into mineral wool nodules;   a main duct for pneumatically transporting discrete mineral wool fibres to said nodulizing means and having an outlet in flow communication with the input of said nodulizing means, and an inlet for discrete mineral wool fibres;   spraying means disposed in said main duct between said inlet and said outlet, for spraying discrete mineral wool fibres being transported;   at least a first degassification elbow disposed in said main duct between said spraying means and said outlet, to control the flow rate of discrete mineral wool fibres to said nodulizing means;   ambient air input means disposed in said main duct between said first degassification elbow and said outlet; and   a pneumatic conveying line having an input in flow communication with the output of said nodulizing means, for transporting mineral wool nodules away from said nodulizing means.   
     
     
       2. An apparatus as claimed in claim 1, wherein said spraying means is capable of delivering a lubricity and cooling agent comprising a silicone oil in a water emulsion. 
     
     
       3. An apparatus as claimed in claim 1, wherein said nodulizing means further comprises: a generally cylindrical housing fixedly mounted around a rotatable shaft;   a plurality of blades disposed on said shaft for processing of said fibres into nodules; and   motion control means attached to said shaft to control the rotational speed thereof.   
     
     
       4. An apparatus as claimed in claim 3, wherein each of said blades is individually pivotally fixed to said shaft. 
     
     
       5. An apparatus as claimed in claim 1, wherein a second degassification elbow in disposed in said main duct between said ambient air input means and said outlet. 
     
     
       6. An apparatus as claimed in claim 5, wherein said first and second degassification elbows and said ambient air input means cooperatively form a flow-rate control means. 
     
     
       7. An apparatus as claimed in claim 6, wherein said degassification elbows comprise exhaust outputs which in flow communication with said pneumatic conveying line. 
     
     
       8. An apparatus as claimed in claim 1, wherein a second spraying means for coating nodules with a dust retaining agent is disposed between the outlet of said nodulizing means and the input of said pneumatic conveying line. 
     
     
       9. A process for making mineral wool nodule insulation with enhanced insulating properties from discrete mineral wool fibres, which comprises the steps of: spraying a lubrication-cooling agent onto a flow of discrete mineral wool fibres;   pneumatically conveying the sprayed fibres at a controlled rate into a nodulizing means, said rate being controlled by conveying the sprayed fibres through at least a first degassification elbow;   cutting and tumbling the fibres into nodules in the nodulizing means by contact with a plurality of blades rotating at a controlled speed and by rubbing upon each other as the fibres travel radially, circumferentially and axially through said nodulizing means; and   pneumatically conveying the nodules from said nodulizing means.   
     
     
       10. A process as claimed in claim 9, additionally comprising spraying a mineral dust retaining agent onto the nodules emerging from the nodulizing means, and pneumatically conveying the nodules away from the nodulizing means. 
     
     
       11. A process as claimed in claim 9, wherein said lubrication-cooling agent comprises a water-silicon oil emulsion. 
     
     
       12. A process as claimed in claim 10, wherein said lubrication-cooling agent comprises water-silicone oil emulsion. 
     
     
       13. A process as claimed in claim 10, additionally comprising packaging said pneumatically conveyed nodules. 
     
     
       14. A process as claimed in claim 10 wherein said mineral dust retaining agent comprises mineral oil. 
     
     
       15. A process as claimed in claim 9, wherein ambient air is added to said fibres after said fibres are conveyed through said first degassification elbow, but before said fibres are conveyed to said nodulizing machine. 
     
     
       16. A process as claimed in claim 15, wherein said fibres are conveyed through at least one further degassification elbow after ambient air is added but before said fibres are conveyed to said nodulizing machine.